Advanced Co-Based Nanocrystalline Soft Magnetics for Extreme Temperature Inductor Applications

The NASA Hot Operating Temperature Technology (HOTTech) program seeks to push existing state-of-art electronic component technologies beyond current capabilities, with targeted operating temperatures of 500C or greater for at least 60 earth days of operation to enable robotic exploration of high temperature environments such as the Venus surface, Mercury, or the deep atmosphere of Gas Giants. As active semiconductor devices realize high temperature capability, advances in passive electronic components (inductors, capacitors, and resistors) become increasingly important. For this reason, NASA HOTTech specifically identifies a need for high temperature passives, including inductors, for applications within high temperature electronics. For inductive components, there exists no published demonstrations of magnetic materials capable of extended operation at T=500C+ at high switching frequencies (f>~1kHz) relevant for power dense (reduce payload) high-speed electric motors, transformers, and inductors, or magnetic sensors. The proposed program addresses this gap through magnetic materials and manufacturing research, focused on newly developed and patented Co-rich based nanocrystalline alloy systems, complemented by inductor device design and demonstrations also leveraging the latest advances in high temperature packaging and windings. At program start, high temperature inductor technologies are estimated at Technology Readiness Level (TRL) of 3 based on early proof of concept studies by project partners. At program conclusion, TRL of 5 is estimated based on testing in application relevant conditions with a clear path to further maturation and near-term commercialization through strategic partnerships with a commercialization partner (CorePower Magnetics), an end-user (Raytheon), and NASA. Capabilities and limitations of existing soft magnetic alloys for high temperature surface planetary exploration missions will also be clarified to guide future research. Specifically, we propose to benchmark existing soft magnetic materials for NASA HOTTech high temperature operation under relevant testing and environmental conditions while pursuing new soft magnetic nanocrystalline alloys, advanced manufacturing methods, and component designs to enable high frequency inductive components for T=500C+ high temperature electronics. The program seeks to accomplish the following objectives targeted for NASA HOTTech operational requirements of T=500C for at least 60 days: Objective #1: Benchmark material and magnetic property stability after exposure to simulated 500C Venusian atmosphere at NASA Glenn Extreme Environment Rig (GEER) for commercial bulk crystalline (FeCo-,FeSi-,FeCr-based), and existing nanocrystalline (FeCo-,Co-based) alloys. Objective #2: Develop new high temperature optimized nanocomposite alloy chemistries and demonstrate capability for high temperature stable permeability engineering of magnetic cores through advanced manufacturing techniques that include both field and tension annealing. Objective #3: Design and fabricate prototype inductors based upon existing commercial and state of art alloys, as well as with newly developed nanocomposite alloy systems, leveraging commercial advances in packaging, thermal management, and insulating windings. Demonstrate successful operation of high temperature inductors in application relevant excitation conditions. To successfully accomplish stated objectives and enable rapid commercial adoption of developed technologies, a combined academic (University of Pittsburgh), industry (Raytheon Technologies, CorePower Magnetics), and NASA laboratory integrated research team has been assembled to leverage on-going efforts, established capabilities, and domain specific expertise. In addition to space applications these high temperature materials and inductors are also relevant for hybrid-electric propulsion and Air Force power electronics applications.

Developing Instrument or spacecraft technology to improve measurements for future planetary science missions

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